Method and Apparatus for Material Handling for a Food Product Using High Pressure Pasteurization

ABSTRACT

A method and apparatus for high-pressure pasteurization utilizes a basket ( 40 ) for holding food packages ( 95 ). The basket ( 40 ) is transported on a cart ( 60 ) from a loading station ( 90 ), to the high-pressure pasteurization processing apparatus ( 10 ) and back to an unloading station ( 100 ). Two robots ( 17, 18 ) are utilized to reduce cycle time of the high-pressure pasteurization vessels ( 11 ).

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to high pressure pasteurization andmore specifically to a method and apparatus for use while utilizing highpressure pasteurization for food products.

2. Description of the Prior Art

Consumers desire high quality, minimally processed foods with freshcharacteristics and little to no additives. High pressure pasteurization(“HPP”), also known as high hydrostatic pressure processing orultra-high pressure processing, is being used to pasteurize foods atelevated pressures of approximately 30,000 to 130,000 pounds per squareinch (“psi”) for a specified temperature and time. The pressure isapplied through a pressure medium such as a liquid or a gas. Under theseconditions, HPP has been found to be effective in inactivating manypathogenic microorganisms commonly found in foods. As compared to cannedfoods or pasteurized juices and milk, HPP significantly reduces theprocess temperature and time, which results in foods with improvedcharacteristics such as better retention of freshness, flavor, texture,color, and nutrients.

HPP is based on the Le Chatelier principle which states that a system atequilibrium adjusts when subjected to a stress and that actions thathave a net volume increase will be retarded and actions that have a netvolume decrease will be enhanced. HPP utilizes isostatic or hydrostaticpressure which is equal from every direction. Isostatic compressiontransfers pressure instantly and uniformly throughout the pressuremedium providing a non-thermal process alternative for thepasteurization of temperature-sensitive foods. Foods suspended in thepressure medium are assumed to follow the isostatic principle. The basisfor using the HPP process as a pasteurization method is based on theassumption that the product also follows the isostatic rule, whichstates that isostatic pressure is instantly and uniformly transmittedthroughout the pressurized medium and the enclosed food product,regardless of size, shape or physical state of the food.

During HPP, foods are subjected to pressures up to 130,000 psi, and thepressure destroys pathogenic microorganisms by interrupting theircellular functions. Within a living bacteria cell, many pressuresensitive processes such as protein function, enzyme action, andcellular membrane function are impacted by high pressure resulting inthe inability of the bacteria to survive. Small macromolecules that areresponsible for flavor, order, and nutrition are typically not changedby pressure.

HPP is gaining in popularity within the food industry because of itscapacity to inactivate pathogenic microorganisms with little to no heattreatment, resulting in the retention of most of the nutritional andsensory characteristics of fresh foods without sacrificing shelf-life ofthe foods.

One of the advantages of HPP is that pressure transmission is relativelyinstantaneous and uniform, and HPP is not controlled by product size andis effective throughout the foods. HPP also offers several advantagesover traditional thermal processing including reduced process times,minimal heat damage, and retention of freshness, flavor, texture, color,and nutrients.

To date, the process for HPP has been on a much smaller scale than istypically needed for processing large quantities of food. The presentinvention addresses this problem and provides for a new method and anapparatus for use during the high pressure pasteurization.

SUMMARY OF THE INVENTION

In one embodiment, the invention is a basket for holding product for usein high pressure pasteurization. The basket includes an elongatecylindrical body member. The body member has first and second ends andthe body member defining an inner cavity. A dividing member isoperatively connected to the body member, the dividing member separatingthe inner cavity into a first sub-chamber and a second sub-chamber.First and second end members are operatively connected proximate to thefirst and second ends of the body member. The end members having acircular surface extending radially outward further than the bodymember, thereby defining a circular surface for rotating the basket on acart. The body member has a plurality of openings, wherein water mayenter into the inner cavity. A door is operatively connected to the bodymember, wherein product is insertable into the inner cavity.

In another embodiment the invention is a method of processing a productfor processing in a high pressure pasteurization vessel. The methodincludes positioning an elongate cylindrical basket on a movable cart,the basket being positioned in a horizontal position. The product isloaded inside of the basket while the basket is still in the horizontalposition. The cart and basket are moved, while the basket is still inthe horizontal position to the high pressure pasteurization apparatus.The baskets are then oriented vertically. The basket is loaded into thehigh pressure pasteurization vessel. The product is subjected to highpressure pasteurization. The basket is removed from the high pressurepasteurization vessel and the basket is oriented horizontally. The cartand basket are moved, while the basket is in a horizontal position to anunloading station. Product is unloaded from the basket while the basketis still in the horizontal position.

In another embodiment the invention is a method of processing product ina high pressure pasteurization vessel. The product is carried in abasket. The method includes positioning a gantry over at least a firsthigh pressure pasteurization vessel. A first robot is carried on thegantry. A second robot is also carried on the gantry. A first basket ispositioned for pickup by the first robot. The first basket is picked upby the first robot and placed in the at least first high pressurepasteurization vessel. The product is processed in the first basket inthe at least first high pressure pasteurization vessel. The first basketis removed with the second robot. While the second robot is removing thefirst basket, a second basket is picked up with the first robot and thesecond basket is placed in the at least first high pressurepasteurization vessel, whereby cycle time is reduced in the at leastfirst high pressure pasteurization vessel and is able to be utilized agreater percentage of time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the high pressure pasteurization systemof the present invention;

FIG. 2 is a perspective view of a basket for use in the high pressurepasteurization system shown in FIG. 1;

FIG. 3 is a perspective view of the basket shown in FIG. 2 with the dooropen;

FIG. 4 is a perspective view of a cart used in conjunction with the highpressurization system shown in FIG. 1;

FIG. 5 is a perspective view of the cart shown in FIG. 4 with thebaskets shown in FIG. 2 in position on the cart;

FIG. 6 is a perspective view of a lifting mechanism utilized inorienting the cart while use in the high pressure pasteurization system;

FIG. 7 is a perspective view of the lifting mechanism shown in FIG. 6 inan extended position;

FIG. 8 is a perspective view of a loading station; and

FIG. 9 is a perspective view of an unloading station.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to the drawings, where unlike numerals represent like partsthroughout the several views, there is generally disclosed at 10 a highpressure pasteurization (HPP) and processing apparatus. The HPPprocessing apparatus 10 includes a plurality of HPP vessels 11. The HPPprocessing apparatus 10 includes at least two and preferably more HPPvessels 11. The HPP vessels 11 are well known in the art, and an exampleof such a vessel is 215L model sold by Avure of Kent, Wash. A gantryassembly 12 includes a first rail 13 and a second rail 14 respectivelysupported by posts 15 and 16. The gantry supports two robots 17 and 18.The first robot 17 is supported on two mounting members 17 a and thesecond robot 18 is supported on two mounting members 18 a. The mountingmembers 17 a and 18 a provide for longitudinal movement along the rails13 and 14. The mounting member 17 a also provides for rails so that therobot may move perpendicular to the rails 13 and 14. Throughout thisapplication, the x axis will refer to movement which will be parallel tothe rails 13 and 14, the y axis movement parallel to the mountingmembers 17 a and the z axis vertical movement.

The HPP vessels have openings 11 a to receive baskets 40. Communicationsand power to the robots 17 and 18 are provided via wires (not shown).The robots are controlled via a computer (not shown). Suitable robots 17and 18 may be utilized, one example of which is sold by Parker Hannifinof Irwin, Pa. The robots 17, 18 are also mounted on supports 19, 20. Thesupports 19, 20 can travel in the z axis direction, thereby moving therobots 17, 18 vertically.

A safety screen 21 may be positioned around the HPP processing apparatus10. The safety screen 21 has suitable openings to allow access to theHPP processing apparatus 10. The safety screen 21 has two openings 22and 23 that provide an outlet and opening 24 for an outlet for a cart 60which holds the baskets 40.

Referring now to FIGS. 2 and 3, there is shown in more detail the basket40. The basket 40 is shown in a closed position in FIG. 2 and in an openposition FIG. 3. The basket is in a general shape of a cylinder. Thebasket includes a first elongate member 41 and a first cover section 42and a second cover section 43. The elongate member 41 is operativelyconnected at a first end to a first end plate 44 and at its other end toa second end plate 45. The elongate member 41 and cover sections 42, 43and end plates 44, 45 are typically made of stainless steel. A rim 44 aand a rim 45 a are operatively connected to the end plates 44 and 45respectively. The rims 44 a, 45 a are preferably made from an ultra-highmolecular weight plastic and are sized to extend beyond the elongatemember 41 to prevent scarring when the basket 40 is inserted into theopening 11 a. The rims are suitably connected by means such as screws 46to their respective end plates. Operatively connected to the first endplate 44 is a circular member 47. The circular member 47 functions as apickup point for the basket 40 when being engaged by the robots 17, 18.A first slot 41 a and a second slot 41 b are formed in the elongatemember 41 proximate a first edge 41 c. Similar first and second slotsare formed along the second edge 41 d. Slots 41 a provide for a path forthe second cover 43 to slide longitudinally. Similarly, slots 41 bprovide a path for the first cover section 42 to slide longitudinally. Arectangular opening 41 e is formed at the end of the first cover section42 and provides for an opening to engage a latch 48. The latch 48 has ahandle 49 to allow the latch to pivot. The handle 49 is rotated to theleft, as viewed in FIG. 3, to lower the latch 48 and allow the coversection 42 to slide adjacent the end plate 44. When the handle 49 isthen rotated to the right it engages the latch 48 and holds the firstcover section 42 in position. The orientation of the basket 40 is eitherhorizontal or the first end plate 44 is upward. Therefore the secondcover section 43 is held in place by gravity against the second endplate 45 when the basket 40 is in an upright position. A partition 50 iscircular and is sized and configured to fit inside of the elongatemember 41 and is operatively connected thereto by suitable means such aswelding. The partition 50 has a plurality of holes 50 a. Further, thereare openings 50 b formed along the inner perimeter of the elongatemember 41. Since during the processing of a package in the HPP vessel11, it is necessary that the water, under pressure, come in contact withproduct inside of the basket, a plurality of holes are formed in theelongate member 41. Holes 42 a are formed in the cover section 42 andholes 43 a are formed in the cover section 43. However, in the figures,all of the holes are not shown. The holes 42 a and 43 a would extendacross the sections 42, 43. Further, the holes 41 f extend around thecomplete circumference of the elongate member 41 as well as extendingalong the horizontal length of the elongate member 41. Such a placementof holes 42 a, 43 a, and 41 f is well known in the art and has not beenshown completely for ease of preparation of the drawing.

Referring now to FIGS. 4 and 5, there is shown a cart 60. The cart 60has four caster wheels 61 that are operatively connected to and supporta frame 62. A yoke 63 is operatively connected to a cross member 62 a ofthe frame 62. A T-handle 64, having an inverted U-shaped base 64 a, isoperatively connected to the yolk 63. Two pins 64 b are operativelyconnected between the legs of the base 64 a and are positioned in slots63 a and 63 b formed in the yoke 63. The handle 64 is then moveable fromthe stored position, as shown in FIGS. 4 and 5 to a transport positionby simply lifting up on the handle and pivoting downward about the lowerpin 64 b.

Eight rollers 65 are rotatably mounted on shafts 66. The shafts areoperatively connected, by means well known in the art such as welding,to a support member 67 that is operatively connected to and supported bythe frame 62. As shown in FIG. 5, the baskets 40 are supported on thecart 60 by the rims 44 a and 45 a contacting the rollers 65. The baskets40 are then able to be rotated on the rollers 65. An L-shaped cover orshield 68 extends substantially the length of the cart and is positionedso as to be adjacent the rims 44 a and 45 a as well as the elongatemember 41. The cover 68 has a horizontal section 68 a and a verticalsection 68 b. The cart 60 has two bottom members 69 upon which thebaskets 40 rest, when the cart 60 is moved to a vertical position.

Referring now to FIGS. 1, 6 and 7, two tilting mechanisms 70 arepositioned in each of the cells of the HPP processing apparatus 10, oneon the unprocessed side A and another on the processed side B. Thetilting mechanisms 70 are only shown in the first cell, but it isunderstood they would also be in each of the other cells. It isappreciated that any suitable tilting mechanism may be used to changethe orientation of the baskets 40 from horizontal to vertical and thenfrom vertical to horizontal. The tilting mechanism 70 includes a baseframe 71 that is suitably secured to the floor or mounting surface bybracket 71 a and bolts (not shown). A moveable frame 72 is rotatablymounted on a pivot bar 73 by means well known in the art. A cylinder 74has an extension arm 74 a, that when extended, will rotate the frame 72to an upright position as shown in FIG. 7. A latch member 75 ispivotally mounted on bar 75 a. A second cylinder 76 has an extension arm76 a, that when extended, will cause the bar 75 a to rotate and therebycause the latch mechanism to rotate and engage and hold the cart 60against the movable frame 72. Then, when the cylinder arm 74 a isextended the latch member 75 will hold the cart 60 in position as thecart rotates from a horizontal position to a vertical position. A thirdcylinder 77 has an extension arm 77 a that is utilized to rotate thecross-member 78 with its two supports 78 a from an up position, as shownin FIGS. 6 and 7 to a horizontal position (not shown). The cross member78 a pivots about point 79. When the arm 77 a is extended and the crossmember 78 rotates 90 degrees to the right, as shown in FIG. 6, the cart60 is then able to be moved off of the tilt mechanism 70. A handle guide80 extends the length of the moveable frame 72. A second handle guide 81is secured to the cross member 78, so that when the cross member 78rotates 90 degrees to the right, the handle guide 81 is parallel to thehandle guide 80. The handle guides 80 and 81 prevent the T-handle 64from falling down in between the movable frame 72 as the cart is beingpushed off of the tilting mechanism 70. The cylinders 74, 76 and 77 maybe operated by suitable computer controls or manually.

The operation of loading the baskets 40, processing the baskets 40 inthe HPP vessels 11 and the unloading of the baskets 40 will now bedescribed in more detail.

Referring now to FIG. 8, there is shown a loading station generallydesignated at 90. The loading station includes a conveyor 91 forreceiving a food package 95 at its first end 91 a. The food package 95may be supplied to the conveyor 91 by any suitable means well known inthe art. The food package includes a product that is any suitable foodproduct in a suitable package. The packages typically wrap the food in asuitable plastic. Such food packages 95 are well known are in the art. Acart 60, with two baskets 40, is positioned into a guide/stop 92. Theconveyor 91 is positioned between the two baskets 40 and the secondbasket is hidden from view in FIG. 8. There are two optional platforms93 and 94 that provide steps for the workers to stand next to therespective baskets 40. In order to load the basket 40, one of the twocover sections 42, 43 is moved to an open position, such as shown inFIG. 3. The worker is then able to pull the food packages 95 from theconveyor 91 into the interior of the basket 40. Once one section isfilled, the covers are moved to the opposite direction and the secondsection is filled. The rollers 65 allow the worker to rotate the basketso that the edge 41 c or 41 d is below the height as the conveyor 91.The edge 41 c or 41 d may easily be oriented to the height desired bythe worker. The worker is able to load the basket 40 by having a pullingmotion, which is ergonomically better than a pushing motion. Once bothsections of both baskets 40 are loaded, the cover sections 42, 43 areclosed and latched and the cart 60 is removed from the guide 82 andanother cart 60 is brought in for loading. The partition 50 provides foran intermediate load-bearing member so that later in the process whenthe baskets are vertical, the bottom food package only has the weight ofone-half of the food packages in the basket 40. It is of courseunderstood that more partitions 50 could also be used to further limitthe weight on the bottom packages.

The food packages 95 are loaded in a horizontal position and aretransported from the loading station 90 to the HPP processing apparatus10 while still in the horizontal position.

The processing through the HPP processing apparatus 10 will now bedescribed. Carts 60 with baskets 40 full of unprocessed food packages 95are brought to the “unprocessed” side A of the HPP processing apparatus10. The “processed” side B is the side where the carts 60 are removedafter the food packages 95 in the baskets 40 have been processed. Byhaving an unprocessed side and a processed side, the potential forinadvertently treating an unprocessed basket 40 as processed iseliminated. The cart 60 is brought into the opening 24 with the baskets40 still in a horizontal position. A tilting mechanism 70 is positionedto receive the cart 60 after it is passed through the opening 24. Thetilting mechanism 70 is then activated and the latch mechanism 75secures the cart 60 to the tilt mechanism 70 and moves the cart 60 andbaskets 40, for the first time, to a vertical orientation. One of therobots 17, 18 then is oriented along the x axis and y axis over thecircular member 47 of the basket 40. The robot 17, 18 is lowered and therobot 17, 18 grasps the circular member 47. The robot 17, 18 then liftsthe basket 40 upwards and moves it along the x axis and y axis over theopening 11 a where the robot 17, 18 then lowers the basket 40 into theHPP vessel 11 through the opening 11 a. The rims 44 a and 45 a helpprevent any scratching of the HPP vessel 11. The HPP vessel 11 then goesthrough its cycle to process the food packages 95 inside of the basket40. After the cycle is completed one of the robots 17, 18 will again bepositioned over the opening 11 a and go downwards and grasp the circularmember 47 a in order to lift the basket 40 out of the HPP vessel 11. Therobot 17, 18 will then move the basket 40 to the second tiltingmechanism 70 positioned on the process side B. The tilting mechanism 70and cart 60 are oriented vertically. When two baskets 40 are on the cart60, the tilting mechanism 70 is returned to horizontal and the cart 40,with two processed baskets 60, are pushed off of the tilting mechanism70 through opening 23. While this unloading of the basket 40 from theHPP vessel 11 is occurring using one of the robots 17, 18, the other ofthe robots 17, 18 is simultaneously picking up another basket 40 fromthe unprocessed side A and is placing it in the HPP vessel 11. By usingtwo robots to perform the unloading and loading function simultaneously,the HPP vessel 11 is able to be more fully utilized a greater percentageof the time. The cycle time of the HPP vessel 11 is reduced. When bothbaskets on the cart 60 from the unprocessed side are processed, thetilting mechanism 70 is returned to horizontal along with the cart 60 ispushed off of the tilting mechanism and the empty cart 60 is moved outof opening 22. As an example, a vessel may have a cycle time ofapproximately seven minutes. This will of course depend upon the productbeing processed as well as the performance of the vessel. The time toload and unload a vessel using only one robot would be approximately oneminute and seven seconds, whereas using the present invention of tworobots to load and unload a basket at the same time the load and unloadtime is reduced to 36 seconds. It is understood that depending on eachHPP and processing apparatus that may be utilized, these times may vary.

Once the carts 60 on the processing side B are full, the tiltingmechanism 70 is used to lower the carts 60 back the horizontal position.The carts 60 are then removed through the openings 22 and 23. The smallfence 25 is designed to warn workers from entering the openings 22, 23,but still allow the carts 60 to pass over.

The two robots 17 and 18 are able to supply baskets 40 to multiple HPPvessels 11. It is understood that any suitable programming may be usedto provide for the proper sequencing just described.

Once the food packages 95 are processed and removed from the processside B of the HPP processing apparatus, they are moved by the cart,while still in a horizontal position, to the unloading station, shown inFIG. 9. Referring to FIG. 9, there is shown generally an unloadingstation 100. As viewed in FIG. 9, a cart 60, having two baskets 40, isbrought in from the left up to when the cart 60 contacts a guide/stop101. Two conveyors 102 and 103 are adjacent the baskets 40. A worker,standing next to the conveyor 102 or 103, then opens the sections 42 and43 sequentially and removes the food packages 95 inside of the basket40. Again, the worker may rotate the basket 40, on their circular rims41 a, 41 b, on the cart so as to align the first edge 41 c or 41 d evenwith the height on the conveyor. The worker is able to unload the basket40 by having a pulling motion, which is ergonomically better than apushing motion. The packages 95 then proceed down the conveyors 102-103for further packaging, by means well known in the art. After the baskets40 have both been unloaded, the cart 60 is removed and another cart withfull baskets 40 is provided.

By keeping the baskets 40 in a horizontal position throughout, exceptfor the one time where the baskets are moved to a vertical position, toallow for insertion into the HPP vessel 11, the amount of stress on thefood package 95 is minimized, thereby lessening the chances ofpuncturing or tearing the food package 95.

The invention has described the capabilities of using a system thatincludes two robots 17 and 18. It is understood that by suitableprogramming, the system may also be set up to utilize only one robot inthe event of the failure of the other robot. This would of course reducethe turnaround time, but still allows for the operation of theprocessing apparatus 10 when one robot has failed, or is being serviced.

The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

1. A basket for holding product for use in high pressure pasteurization,the basket comprising: a) an elongate cylindrical body member, the bodymember having first and second ends, the body member defining an innercavity; b) a dividing member operatively connected to the body member,the dividing member separating the inner cavity into a first subchamberand a second subchamber; c) first and second end members operativelyconnected proximate to the first and second ends of the body member, theend members having a circular surface extending radially outward furtherthan the body member, thereby defining a circular surface for rotatingthe basket on a cart; d) the body member having a plurality of openings,wherein water may enter into the inner cavity; and e) a door operativelyconnected to the body member, wherein product is insertable into theinner cavity.
 2. The basket of claim 1, further comprising the endmembers constructed from ultra high molecular weight plastic, whereinthe high pressure vessel is less likely to be scarred when the basket isinserted therein.
 3. The basket of claim 1, further comprising a robotpick-up member operatively connected to one of the first and secondends.
 4. The basket of claim 1, the door further comprising a first doormember and a second door member, the door members sliding with respectto each other, wherein when the first door member is moved to be alignedwith the second door member, the first subchamber is exposed for loadingand unloading and when the second door member is moved to be alignedwith the first door member, the second subchamber is exposed for loadingand unloading.
 5. A method of processing product in a high pressurepasteurization vessel, the product carried in a basket, the methodcomprising: a) positioning a gantry over at least a first high pressurepasteurization vessel; b) providing a first robot carried on the gantry;c) providing a second robot carried on the gantry; d) positioning afirst basket for pick-up by the first robot; e) picking up the firstbasket by the first robot and placing the basket in the at least firsthigh pressure pasteurization vessel; f) processing the product in thefirst basket in the at least first high pressure pasteurization vessel;g) removing the first basket with the second robot; h) while the secondrobot is removing the first basket, picking up a second basket with thefirst robot and placing the second basket in the at least first highpressure pasteurization vessel, whereby cycle time is reduced and the atleast first high pressure pasteurization vessel is able to be utilized agreater percentage of time.
 6. The method of claim 5, wherein thebaskets are elongate cylindrical baskets.
 7. The method of claim 6,further comprising a second high pressurization vessel that is loadedand unloaded by both the first and second robots.